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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS1981

Low NO/x/ combustion systems for burning heavy residual fuels and high-fuel-bound nitrogen fuels

Design concepts are presented for lean-lean and staged rich-lean combustors. The combustors are designed for the dry reduction of thermal NO(x), control of NO(x) from fuels containing high levels of organic nitrogen, and control of smoke from low hydrogen content fuels. The combustor concepts are tested with a wide variety of fuels including a middle distillate, a petroleum based heavy residual, a coal derived synthetic, and ratios of blends of these fuels. The configurations of the lean-lean and rich-lean combustion systems are provided along with a description of the test rig and test procedure.

White, D. J.↗
DOE OSTI2018

EISA (Energy Independence and Security Act) compliant ethanol fuel from corn stover in a depot-based decentralized system

Cellulosic biofuels face significant problems of feedstock aggregation and logistics leading to poor economies of scale. The current model is based on relatively small biorefineries using locally-gathered feedstocks. Here, we examine the potential capacity of a hypothetically distributed, depot-based, biorefinery system to produce cellulosic ethanol from corn stover in the United States Midwest. The local depots serve to aggregate, pretreat and densify biomass (via pellets), which are collected, transported, and fed to a few very large, cellulosic ethanol biorefineries. We found that a corn stover-based depot system would help establish one or two very large-scale biorefineries capable of processing about 8-12% of total corn stover available in the United States Midwest. About 55-153 depots could supply the pretreated pellets to each distributed biorefinery leading to an annual production of 1.02 - 2.91 billion liters of cellulosic ethanol. Most of the participating depots would be located in Illinois and Iowa. The ethanol selling price in this depot-based biorefinery system would varys between U$S 0.67 and U$S 0.72 liter-1. The estimated range of GHG savings from cellulosic ethanol in the depot system compared to gasoline was 3.35-4.84 Tg CO2 year-1. In addition of being economically competitive, a distributed, depot-based, biorefinery system could meet the 60% GHG reduction requirement of the U.S. Energy Independence and Security Act (EISA).

Biorefinery, Cellulosic biofuel, Corn stover, Dist↗
DOE OSTI2021

Catalytic Hydroprocessing of Single-Cell Oils to Hydrocarbon Fuels : Converting microbial lipids to fuels is a promising approach to replace fossil fuels

Microbial lipids hold great promise as biofuel precursors, and research efforts to convert such lipids to renewable diesel fuels have been increasing in recent years. In contrast to the numerous literature reviews on growing, characterising and extracting lipids from oleaginous microbes, and on converting vegetable oils to hydrocarbon fuels, this review aims to provide insight into aspects that are specific to hydroprocessing microbial lipids. While standard hydrotreating catalysts generally perform well with terrestrial oils, differences in lipid speciation and the presence of co-extracted compounds, such as chlorophyll and sterols, introduce additional complexities into the process for microbial lipids. Lipid cleanup steps can be introduced to produce suitable feedstocks for catalytic upgrading.

09 BIOMASS FUELS↗
DOE OSTI2018

U.S. energy sector impacts of technology innovation, fuel price, and electric sector CO2 policy: Results from the EMF 32 model intercomparison study

We study the impact of fuel prices, technology innovation, and a CO2 emissions reduction policy on both the electric power and end-use sectors by comparing outputs from four U.S. energy-economic models through the year 2050. Achieving innovation goals decreases CO2 emissions in all models, regardless of natural gas price, due to increased energy efficiency and low-carbon generation becoming more cost competitive. For the models that include domestic natural gas markets, achieving innovation goals lowers wholesale electricity prices, but this effect diminishes as projected natural gas prices increase. Higher natural gas prices lead to higher wholesale electricity prices but fewer coal capacity retirements. A CO2 electric power sector emissions cap influences electric sector evolution under reference technology assumptions but has little to no incremental influence when added to innovation goals. Long-term, meeting innovation goals achieves a generation mix with similar CO2 emissions compared to the CO2 policy but with smaller increases to wholesale electricity prices. In the short-term, the relative effect on wholesale prices differs by model. Finally, higher natural gas prices, achieving innovation goals, and the combination of the two, increases the amount of renewable generation that is cost-effective to build and operate while slowing the growth of natural-gas fired generation, which is the predominant generation type in 2050 under reference conditions.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2016

Thrust I Fuel Merit Function: A Tool for Ranking Fuel-Enabled Efficiency Gains When Multiple Fuel Properties Vary Simultaneously

This is one of a series of reports produced as a result of the Co-Optimization of Fuels & Engines (Co-Optima) project, a Department of Energy (DOE)-sponsored multi-agency project initiated to accelerate the introduction of affordable, scalable, and sustainable biofuels and high-efficiency, low-emission vehicle engines. The simultaneous fuels and vehicles research and development is designed to deliver maximum energy savings, emissions reduction, and on-road performance.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Gasoline Engine and Fuels Offering Reduced Fuel Consumption and Emissions: Vehicle Modeling Final Report

The Gasoline Engine and Fuels Offering Reduced Fuel Consumption and Emissions (GEFORCE) project was proposed in response to the U.S. Department of Energy’s Funding Opportunity Announcement 0991 by a team made up of the members of the Coordinating Research Council (CRC) and the research staff at Oak Ridge National Laboratory (ORNL.) The project focused on investigating the potential benefits that might be attained through synergistic use of specific engine technology together with fuels formulated to represent potential directions that high-octane fuels of the future might progress. A stated objective in the DOE FOA was to demonstrate a 25% reduction in petroleum consumption through optimization of the engine technologies together with a suitable fuel. An advanced engine was constructed and used with a matrix of research fuels to investigate potential avenues for efficiency improvement. The engine incorporated technologies expected to become mainstream for boosted engines in the next 10 to 20 years. These included increased compression ratio, a two-stage turbocharger, and cooled external exhaust gas recirculation (EGR). The fuel matrix was designed to investigate impacts from research octane number (RON), volumetric ethanol content, and the final boiling point of the fuel. The engine calibration was optimized for each fuel individually and data collected to enable vehicle system modelling that projected energy consumption, fuel economy, tailpipe CO₂ emissions, and impact on petroleum consumption for an industry-average mid-size sedan. The engine calibration and data collection were carried out at IAV in Michigan and is the subject of a separate report. IAV provided the engine data to Oak Ridge National Laboratory to support the vehicle modelling portion of the project. The vehicle modelling results show the following trends: Ethanol content does have a consistently strong influence on the fuel economy results for all cycles and all fuels. Among the fuels of a nominal RON level, increasing ethanol content consistently lowers fuel economy, with the 30% ethanol fuels always providing the lowest fuel economy for a given RON level. However, in some cases the energy consumption improvement allows the 30% ethanol fuels to match the fuel economy of the ethanol-free fuel P. These observations underscore the importance of both engine efficiency and fuel volumetric energy content on vehicle fuel economy.; There was no consistent trend in the projected energy consumption results for differences in fuel T90 for all fuels and cycles. Fuel economy projections did show a consistent trend, with the higher T90 fuel providing slightly greater fuel economy when compared to the low T90 fuel of the same ethanol content. The observed trends were consistent with differences in the heating value of the fuels.; The 102-RON fuels provided reduced energy consumption and greater fuel economy for the advanced engine on all drive cycles. The engine compression ratio of 11.5 was higher than would typically be used in a turbocharged engine when 92-RON fuel use is expected. Hence, the engine experiences more efficiency degradation from knock avoidance when using the 92-RON fuels. This degradation causes the fuel economy results for the 92-RON fuels to be lower than those for the 102-RON fuels.; Fuels E and F (92-RON, 30% ethanol) are projected to achieve 10% or greater reduction in petroleum consumption, with fuels K (102-RON, 30% ethanol) and O (97 RON, 30% ethanol) achieving greater than a 20% reduction. Fuel L (102-RON, 30% ethanol) achieves greater than 25% reduction, meeting the petroleum reduction target of the project. All of the fuels that achieve 10% or greater reduction in petroleum consumption are 30% ethanol blends.; Increasing final boiling point increased fuel economy at fixed ethanol content when the 102-RON fuels were used. This trend is a result of differences in the volumetric energy content of the fuels and the projected energy consumption values for the fuels. In the case of the 102-RON fuels, increasing final boiling point also resulted in an increase in the energy content of the fuel. There was not a consistent trend between the energy content and final boiling point for the 92-RON fuels at fixed ethanol content.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2019

Single-Fuel Reactivity Controlled Compression Ignition Combustion Enabled by Onboard Fuel Reformation (Final Report)

Reactivity-Controlled Compression Ignition (RCCI) is a promising new advanced, low temperature combustion mode that offers efficiencies equal to or greater than conventional diesel combustion, but significantly lower soot and NOx emissions. Additionally, RCCI has enhanced controllability over the combustion process compared to some of the other advanced combustion modes. Therefore, RCCI combustion has the potential to be of great benefit to the public by increasing the efficiency and reducing the harmful pollutant emissions from transportation. However, RCCI combustion achieves this favorable level of performance through the use of two distinct fuels (e.g., diesel and gasoline, diesel and natural gas, or diesel and ethanol). In a vehicle application, RCCI therefore requires two different fuel tanks and fuel injection systems, which presents a significant drawback to the commercialization RCCI. This project proposed a new concept to enable RCCI combustion from a single parent fuel stored onboard the vehicle in a single fuel tank. Specifically, the parent fuel would be stored in the fuel tank and one branch of the fuel system would deliver the parent fuel, unaltered, to the cylinder, while a second branch of the fuel system would route the parent fuel through a fuel reformer to chemically react the fuel into a gaseous fuel mixture, called “reformate”, that has different properties from the original parent fuel. In this way, there can be two fuels at the engine that have different properties, but only one parent fuel needs to be stored and refilled in the vehicle. This initial, exploratory investigation into the feasibility of this promising new concept included reacting three potential parent fuels (diesel, gasoline, and natural gas) in a fuel reformer and determining the composition of the gaseous reformate fuel that exited the fuel reformer. There are different types of reformation processes, but since this project was a proof-of-concept investigation into the potential of Single-Fuel RCCI and the combustion process in the cylinder, a catalytic partial oxidation (CPOX) reformation process was selected, which is more straightforward to perform and control, and would potentially be easier to implement in a vehicle application compared to other reformation processes. Once the three parent fuels were reformed to varying degrees and their reformate compositions were determined, their autoignition tendencies were experimentally determined by comparing advanced combustion results of the reformate mixtures with known reference fuels. This showed that diesel fuel and its reformate fuel mixture exhibited the largest reactivity separation, which is necessary to enable RCCI combustion in the cylinder. Using diesel fuel as the parent fuel, experimental testing was conducted to provide a better understanding of the operational considerations, benefits, and drawbacks of Single-Fuel RCCI with onboard fuel reformation. The experimental testing was accompanied by computational fluid dynamics and system-level modeling to help complement the experiments and further expand the understanding. The main conclusions are that Single-Fuel RCCI using diesel fuel as the direct injected, high reactivity fuel and diesel’s gaseous reformate mixture as the premixed, low reactivity fuel is viable. The efficiencies were equal to, or sometimes greater than, RCCI with conventional fuel pairs, and the emissions were comparable as well. A key consideration is that gaseous reformate fuel contains a large amount of diluents in the fuel which displace air entering the cylinder and act as EGR inside the cylinder. Additionally, the reactivity separation between diesel and its reformate fuel mixture is larger than diesel-gasoline, but less than diesel-natural gas, and the combustion process therefore responded in a manner that was between the two conventional fuel pairs. Finally, although achievable in the cylinder, there are practical drawbacks or other disadvantages of Single-Fuel RCCI with onboard fuel reformation. First, this project used a CPOX reformation process which is exothermic, meaning that a portion of the fuel’s energy was released in the reformer where it could not be converted into useful work. This constituted an efficiency penalty of the system of on the order of 10% or 4 percentage points. Future research should therefore focus on alternate reforming processes including steam-methane reforming or autothermal reforming where there might not be any energy released in the reformer, or there could even be an energy gain in the reformer (through an endothermic process with waste heat recovery). Practical drawbacks that exist, but were beyond the scope of this preliminary proof-of-concept research project, are the added cost of the fuel reformer, which is a catalyst made of precious metals, transient response of the system, and the lifetime of the fuel reformer.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Drop Analysis of the Advanced Test Reactor Fresh Fuel Shipping Container with Heavier Low-Enriched Uranium Fuel Contents

The Advanced Test Reactor Fresh Fuel Shipping Container (ATR FFSC) is a rectangular stainless steel container used for shipping radioactive material. The container is described in the ATR FFSC Safety Analysis Report (SAR). Per the ATR FFSC SAR, the ATR FFSC is designated a Type AF-96 packaging per the definition of 10 CFR §71.4, and was originally designed to transport high enriched uranium (HEU) reactor fuel elements for the Advanced Test Reactor (ATR), the Advanced Test Reactor Critical (ATRC) facility, the Massachusetts Institute of Technology Reactor (MITR), and the University of Missouri Research Reactor (MURR). The Department of Energy, National Nuclear Security Administration’s (NNSA), Office of Material Management and Minimization (M3) is working with the Idaho National Laboratory (INL) to develop and qualify new low enriched uranium (LEU) fuels and technologies for use in the ATR, ATRC, MITR, and MURR reactors. The LEU fuel elements will weigh significantly more than the current HEU designs and, combined with their associated Fuel Handling Enclosures for packaging, some configurations will exceed the 50 lbf used in the ATR FFSC qualifying drop tests. There are LEU versions of MITR, MURR, and ATR fuel elements. However, for this evaluation, drop analysis of the ATR FFSC with only the heavier ATR Low Enrichment (LOWE) fuel element is considered in this evaluation because the LOWE fuel element is the heaviest of the considered LEU fuel elements. The ATR HEU fuel element and the ATR LOWE fuel element are identical in every design aspect except for the fuel meat inside the 19 fuel plates. The LEU fuel meats are made using a U-10Mo high-density foil rather than uranium dispersed in aluminum in the HEU fuel elements. The high density of the uranium in the LEU fuel meat increases the LOWE fuel element weight to just under 44 lbf (versus the 22.1 lbf weight of the tested ATR HEU fuel element). ATR fuel elements are placed in a thin-gauge aluminum weldment called a "Fuel Handling Enclosure" during packaging. The Fuel Handling Enclosure is used to cover and protect the element during loading and unloading operations. The ATR Fuel Handling Enclosure weighs about 15 lbf per the drawings in the ATR FFSC SAR and the weight is accounted for in this evaluation. Transporting the heavier LEU fuel elements require evaluation of two issues. The first is the effect of the increased mass of the LEU fuel elements on the survivability of the ATR FFSC package following the requisite drop qualifications. The second is the effect of the increased mass of the fuel plates on the fuel element during the same drops. The ATR FFSC containing an ATR HEU fuel element in an ATR Fuel Handling Enclosure was physically dropped multiple times to qualify the container as a Type AF-96 package. The ATR FFSC SAR describes the drop tests performed with an actual ATR HEU fuel element weighing 22.1 lbf contained in a 14.3 lbf Fuel Handling Enclosure for a total payload of 36.4 lbf. Those drop tests showed that the ATR FFSC maintained containment of the ATR HEU fuel element and the fuel element was not significantly damaged. (Containment herein is not defined as a leak tight but is retention of the radioactive contents.) The purpose of the evaluation is to analytically show that, for a similar set of tests, the ATR FFSC maintains containment of the heavier ATR LOWE fuel element and to assess the damage to the fuel element during the drops. The approach was to create finite element analysis (FEA) models that produce the same results as the physical drops. Those models were then used as the benchmarks for the follow-on analyses using the heavier contents. FEA models of the drops of ATR FFSC using up to a 115 lbf fuel element were run and evaluated. Likewise, drops of a LOWE fuel element weighing 44 lbf in the ATR FFSC were run and evaluated. It is important to note that this report was done at the quality level necessary to be included in a nuclear facility safety basis. However, it is not the intent of this report to conclude the suitability of the ATR FFSC for transporting the heavier payloads. This report only describes the results of the FEA as related to the required drop scenarios. Incorporation of the FEA into the safety basis will be evaluated by the ATR FFSC design authority. The physical drop tests of the HEU fuel element and FEA drop analysis for the LOWE fuel element showed noteworthy damage to the fuel plates. An aluminum protective block was conceived to mitigate the damage. The concept requires the blocks to be placed in the fuel element between the end boxes and fuel plates. Additional FEA drop analyses were performed using the protective block. The addition of the blocks is primarily intended to mitigate the damage to the LOWE fuel element fuel plates. However, FEA drop analyses of the ATR HEU fuel element with the blocks were also performed and included for information.

42 ENGINEERING↗
DOE OSTI2023

Engine Operating Conditions, Fuel Property Effects, and Associated Fuel–Wall Interaction Dependencies of Stochastic Preignition

This work for the Coordinating Research Council (CRC) explores dependencies on the opportunity for fuel to impinge on internal engine surfaces (i.e., fuel–wall impingement) as a function of fuel properties and engine operating conditions and correlates these data with measurements of stochastic preignition (SPI) propensity. SPI rates are directly coupled with laser–induced florescence measurements of dye-doped fuel dilution measurements of the engine lubricant, which provides a surrogate for fuel–wall impingement. Literature suggests that SPI may have several dependencies, one being fuel–wall impingement. However, it remains unknown if fuel-wall impingement is a fundamental predictor and source of SPI or is simply a causational factor of SPI. In this study, these relationships on SPI and fuel-wall impingement are explored using 4 fuels at 8 operating conditions per fuel, for 32 total test points. The fuels were directly injected at two different injection timings: an earlier injection timing that initially targets the piston crown and a later injection timing that targets the cylinder liner. At each injection timing, the engine was operated at both 90°C and 70°C coolant and lubricant temperatures, and 185 and 200 kPa absolute intake manifold pressure. This work serves as an exploratory effort to down select conditions and provide initial fuel properties of interest for a secondary study to explore fuel property specific effects on fuel-wall interaction and SPI propensity. Significant findings from this initial operating condition and fuel property exploratory work are: 1. reduced engine operating coolant and lubricant temperatures, along with 2. retarded injection timings were required to increase SPI propensity. Moreover, at these conditions some fuel specific effects were also observed; specifically, increased ethanol content increased measured dye–wall (i.e., fuel–wall) interaction. However, despite increased dye–wall interaction, the increased volatility of the ethanol containing fuels also reduced the estimated fuel retention in the top-ring zone and associated measured SPI propensity. Thus, the findings of this unique approach to explore relationships between fuel-wall impingement and SPI highlight that SPI propensity is more directly proportional to retained fuel, and not simply fuel–wall impingement. Furthermore, fuel retention was found to be directly influenced by complex fuel property and engine operating condition relationships. Either retarded injection timings and/or increased fuel volatility increased fuel wall-impingement, while less volatile fuels and/or reduced coolant temperatures increased fuel retention. Therefore, for a given operating condition, the data highlights that greater volatile fuels exhibit increased fuel wall impingement without increased fuel retention or SPI propensity, while less volatile fuels could exhibit reduced fuel-wall impingement but increased fuel retention and SPI propensity rates.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2016

Transmutation Fuels Development in the Advanced Fuels Campaign

Metallic fuels have a history of use that spans the entire nuclear age, especially in association with the development of the LMFBR. Initially, metallic fuels were employed due to their ease of fabrication and high heavy metal density (which led to the most favorable breeding efficiencies in fast reactors). During subsequent decades of use, metallic fuel technology has matured significantly, leading to the realization of major benefits in the areas of fuel reliability and burnup, proliferation-resistant recycling, remote fabrication, and passive reactor safety. Such characteristics continue to make metallic fuels a highly attractive technology, especially for use with future sodium fast reactors. Current research and development activities on metallic fuels in DOE's Advanced Fuels Campaign are focused on their potential use for actinide transmutation in advanced SFRs. In such a mission, metallic fuels would be employed as part of a closed fuel cycle into which plutonium and minor actinides (Am, Np) recovered from LWR spent fuel would be incorporated. All actinides in this metallic fuel would be fissioned or transmuted in a fast reactor to eliminate the extremely long-lived, heat-producing actinides in order to reduce the volume, heat load, and radio-toxicity burden on a future geological repository. Thus, the need exists to demonstrate reliable performance of metallic fuels with Pu and minor actinide constituents to very high burnup. As part of this application, there is also a need for a near zero-loss fabrication process, since losses during fuel fabrication are a potential source of long-lived actinides destined for geologic disposal. This paper presents the current state and future direction of the development of metallic fuels for actinide transmutation in the US. Metallic fuels have had a long history of use in sodium-cooled fast reactors. Continued research, development, and design innovation over a period of decades have demonstrated this fuel technology to be safe and reliable to extremely high burnups over a wide range of compositions. Their simple fabrication has historically given them a significant economic advantage over other fuel forms. Research and development on metallic fuels continues, with particular emphasis on showing that this fuel technology can incorporate significant quantities of plutonium and minor actinides for the purpose of efficiently and economically transmuting these elements in a fast-spectrum reactor. New fabrication methods to improve retention of the volatile fuel constituents during the casting process (and reduce waste generation), are being developed. Irradiation testing of the new metallic fuels has so far indicated that the new compositions, although differing significantly both in the quantities of Pu and minor actinides included and in the Zr alloying addition, perform as a function of fission density very analogously to the historic U-Zr and U-Pu-Zr fuels. In the next few years it is anticipated that a new casting furnace prototype will demonstrate that these new metallic fuel alloys can be fabricated at engineering scale, in a remote environment, with no significant fuel loss or waste generation. Irradiation tests currently underway will provide the performance data needed to assess fuel reliability/burnup capability and identify any unique behaviors that are a result of the new compositions. If these future results are consistent with the intermediate data available at present, metallic fuels are expected to continue to be a strong contender for the fuel technology choice of future fast reactors. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

Synthesis and electrochemical characterization of Ti{sub x}Ta{sub y}Al{sub z}N{sub 1-δ}O{sub γ} for fuel cell catalyst supports

Quinary Ti{sub x}Ta{sub y}Al{sub z}N{sub 1-δ}O{sub γ} of various compositions have been prepared by a co-precipitation method followed by ammonolysis. The nitride samples were examined as potential catalyst supports in polymer electrolyte membrane fuel cells. The nitride products crystallized in the rock salt (NaCl) structure over a wide range of compositions. The addition of Ta and Al was highly beneficial towards improving the chemical and electrochemical stability of TiN, without a significant loss of electrical conductivity. Platinum particles were successfully deposited on the (oxy)nitride samples, and the composite samples at some compositions were found to be comparable to Pt/carbon in their stability and catalytic activity even without optimizing the Pt deposition and dispersion processes. - Graphical abstract: The effect of additions of Ta and Al into TiN structure. Shifts the lattice constant, and increases its chemical stability in acidic environment.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2017

ORIGEN-based Nuclear Fuel Inventory Module for Fuel Cycle Assessment: Final Project Report

The goal of this project, “ORIGEN-based Nuclear Fuel Depletion Module for Fuel Cycle Assessment" is to create a physics-based reactor depletion and decay module for the Cyclus nuclear fuel cycle simulator in order to assess nuclear fuel inventories over a broad space of reactor operating conditions. The overall goal of this approach is to facilitate evaluations of nuclear fuel inventories for a broad space of scenarios, including extended used nuclear fuel storage and cascading impacts on fuel cycle options such as actinide recovery in used nuclear fuel, particularly for multiple recycle scenarios. The advantages of a physics-based approach (compared to a recipe-based approach which has been typically employed for fuel cycle simulators) is in its inherent flexibility; such an approach can more readily accommodate the broad space of potential isotopic vectors that may be encountered under advanced fuel cycle options. In order to develop this flexible reactor analysis capability, we are leveraging the Origen nuclear fuel depletion and decay module from SCALE to produce a standalone “depletion engine” which will serve as the kernel of a Cyclus-based reactor analysis module. The ORIGEN depletion module is a rigorously benchmarked and extensively validated tool for nuclear fuel analysis and thus its incorporation into the Cyclus framework can bring these capabilities to bear on the problem of evaluating long-term impacts of fuel cycle option choices on relevant metrics of interest, including materials inventories and availability (for multiple recycle scenarios), long-term waste management and repository impacts, etc. Developing this Origen-based analysis capability for Cyclus requires the refinement of the Origen analysis sequence to the point where it can reasonably be compiled as a standalone sequence outside of SCALE; i.e., wherein all of the computational aspects of Origen (including reactor cross-section library processing and interpolation, input and output processing, and depletion/decay solvers) can be self-contained into a single executable sequence. Further, to embed this capability into other software environments (such as the Cyclus fuel cycle simulator) requires that Origen’s capabilities be encapsulated into a portable, self-contained library which other codes can then call directly through function calls, thereby directly accessing the solver and data processing capabilities of Origen. Additional components relevant to this work include modernization of the reactor data libraries used by Origen for conducting nuclear fuel depletion calculations. This work has included the development of new fuel assembly lattices not previously available (such as for CANDU heavy-water reactor assemblies) as well as validation of updated lattices for light-water reactors updated to employ modern nuclear data evaluations. The CyBORG reactor analysis module as-developed under this workscope is fully capable of dynamic calculation of depleted fuel compositions from all commercial U.S. reactor assembly types as well as a number of international fuel types, including MOX, VVER, MAGNOX, and PHWR CANDU fuel assemblies. In addition, the Origen-based depletion engine allows for CyBORG to evaluate novel fuel assembly and reactor design types via creation of Origen reactor data libraries via SCALE. The establishment of this new modeling capability affords fuel cycle modelers a substantially improved ability to model dynamically-changing fuel cycle and reactor conditions, including recycled fuel compositions from fuel cycle scenarios involving material recycle into thermal-spectrum systems.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

BWR Spent Nuclear Fuel Acquisition and Testing to Support DOE-NE High Burnup Spent Fuel Data Project

The Office of Spent Fuel and Waste Disposition (SFWD) within the US Department of Energy (DOE) Office of Nuclear Energy (NE) established the Spent Fuel and Waste Science and Technology (SFWST) campaign to conduct research and development (R&D) activities related to the storage, transportation, and disposal of spent nuclear fuel (SNF) and high-level radioactive waste. The SFWST program was created within SFWD to address issues of extended or long-term SNF storage and transportation. Some near-term objectives of SFWST are to use a science-based, engineering-driven approach to: Support the enhancement of the technical bases to support the continued safe and secure dry storage of SNF for extended periods; Support the enhancement of the technical bases for retrieving SNF after extended dry storage; Support the enhancement of the technical bases for transporting high burnup (HBU) fuel and transporting low burnup fuel and HBU fuel after dry storage DOE-NE, in partnership with the Electric Power Research Institute, developed the High Burnup Spent Fuel Data Project to perform a large-scale demonstration and laboratory-scale testing of HBU pressurized water reactor (PWR) fuels (exceeding 45 gigawatt-days per metric ton of uranium [GWd/MTU]). Under this project, 25 sister rods—which are rods that have the same design, power histories, and other characteristics—were removed from assemblies at the North Anna Nuclear Power Station and sent to Oak Ridge National Laboratory (ORNL) in January 2016. ORNL performed detailed nondestructive examination (NDE) on all 25 rods. The NDE consisted of visual examinations, gamma and neutron scanning, profilometry and rod length measurements, and eddy current examinations. After completing the NDE, 10 of the sister rods were delivered to Pacific Northwest National Laboratory (PNNL) in a NAC International, Inc. legal-weight truck cask in September 2018 for destructive examination (DE). To date, SFWD work has focused on the PWR fuel that is part of the Sister Rod Test program. No boiling water reactor (BWR) fuel has been tested in the program, and the data needs that were identified for the PWR fuel have not been collected for BWR fuel. The goal to obtain six to nine BWR rods and test them at ORNL will support closing this important data gap. BWR fuel comprises approximately 56% of the total fuel assemblies currently in storage at nuclear power plants in the United States. BWR nuclear fuel and cladding designs and manufacturing are significantly different from PWRs. Differences include the following: BWR fuel pellets are larger than PWR pellets; Variations of Zircaloy-2 (including liners) are used instead of the Zircaloy-4 cladding materials used in PWRs; Clad manufacturing and stress-relief processes are different between PWRs and BWRs; The fuel rod dimensions are different because larger rod diameters and thicker cladding are used in BWRs; BWR fuel typically has lower internal rod pressures and sees vastly different operating conditions than PWR fuel (i.e., two-phase flow); BWR assemblies are “canned,” meaning each assembly is surrounded by a metal fuel channel; BWR cladding is often composed of an inner pure Zr liner that has widely different mechanical properties than the Zircaloy-2 alloy and exhibits a stronger affinity for hydrogen; The BWR SNF generally has more total hydrogen in the cladding/liner than typical PWR fuel; The construction of the PWR and BWR assemblies is vastly different; BWR rods are solidly attached to the assembly nozzles and experience a much different vibration and shock load than PWR rods, which are “floating” within a grid system attached to guide tubes, and the rods sit loosely on the bottom end plates. These numerous differences will affect the way the BWR SNF responds under dry storage preparation processes (e.g., vacuum drying) and during transportation. The results collected in the PWR experimental program must be compared with a subset of similar data collected on BWR SNF to establish a technical basis for whether the larger PWR database is sufficient to bound the BWR SNF end-of-life conditions as is currently assumed for several fuel/clad properties. Changes that occur in both fuel types at HBU could exacerbate any mechanical property differences. As the fuel burnup increases, several changes occur that might affect the performance of the fuel, cladding, and assembly hardware in storage and transportation. These changes include increased cladding corrosion layer thickness, increased cladding hydrogen content, increased cladding creep strains, increased fission gas release, and the formation of the HBU structure at the surface of the fuel pellets. The Nuclear Regulatory Commission (NRC) limits the current maximum rod-averaged burnup to 62 GWd/MTU due to these changes and the lack of data at higher burnups.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Fuel utilization effects on system efficiency in solid oxide fuel cell gas turbine hybrid systems

Here, a computational analysis was conducted to optimize the design of a solid oxide fuel cell - gas turbine hybrid power generator, focusing on the impact that fuel utilization within the fuel cell has on system efficiency and installed costs. This is the first ever design-study considering the effect of fuel utilization on performance, as well as on the optimum power split. This hybrid system attained high electric generation efficiencies (>70%) over a wide range of operating conditions (60% < fuel utilization < 90%) while the fuel cell stack size decreased in proportion to decreasing the fuel utilization. A one-dimensional fuel cell model was used to simulate the fuel cell while GateCycle® was used to simulate the performance of the associated recuperated turbine and various subsystems necessary for thermal management. For each test case, the size of the solid oxide fuel cell, gas turbine, and recuperator, as well as the fuel and air flow rates, hot-air bypass set point, and heat exchange effectiveness in the solid oxide fuel cell manifold were varied to obtain 550 MWe output. In addition, anode recycle, turbomachinery efficiency, and various thermal management options were tested. The maximum system efficiency (75.6%) was attained for the single-pass solid oxide fuel cell with highly efficient turbomachinery when the solid oxide fuel cell used 80% of the incoming fuel. Efficiency was essentially flat from 75% fuel utilization through 85% fuel utilization. Employing anode recycle starting at 65% resulted in roughly 1 percentage point efficiency decrease for each percent increase in fuel utilization. For minimized solid oxide fuel cell degradation, a near 50:50 power split case was studied resulting in 68.6% efficiency and the solid oxide fuel cell using 55% of the incoming fuel. Because of shifting half of the power generation to the gas turbine, the size of the fuel cell stack was reduced by 25% as compared to that at maximum efficiency (80% fuel utilization).

42 ENGINEERING↗
DOE OSTI2020

Reactor and fuel cycle performance of light water reactor fuel with 235 U enrichments above 5%

Recent advances in nuclear fuel materials research, particularly on the topic of accident-tolerant fuels, have brought up potential opportunities for expanding the operating envelope of existing light water reactors. As many of the performance improvements offered by these technologies may be most fully realized by increasing fuel enrichment beyond the standard 5% limit, this paper examines the potential reactor performance and fuel cycle performance of low-enriched uranium oxide fueled light water reactors by generically considering pressurized water reactors with 235 U enrichment from 5 to 7%. Advanced cladding, including accident-tolerant cladding, has the potential to increase fuel burnup limits related to hydrogen in the cladding that coincide with those limits associated with end-of-life reactivity. Therefore, higher enrichment will be necessary in order to realize the higher fuel burnups. This work includes evaluation of the fuel cycle length, discharge burnup, reactivity coefficients, and fuel cycle performance, including radioactive waste and environmental impact metrics per unit energy generated. The analysis was performed using the evaluation metrics from the US Department of Energy Office of Nuclear Energy Fuel Cycle Evaluation and Screening Study. The reactor performance and safety analysis show that enrichments between 5 and 7% would have similar fuel temperature and moderator temperature coefficients. However, the soluble boron coefficient would decrease in magnitude, requiring more corrosive boric acid in the coolant or other methods of reactivity control during the fuel cycle. At these higher enrichments the maximum burnup at the rim of the fuel pellet would increase by almost a factor of two, which is expected to impact the formation of high-burnup structure in the fuel and the corresponding thermo-mechanical fuel properties. The fuel cycle performance assessment shows that increasing enrichment reduces the quantity of high-level waste disposed per unit energy generated, but it increases the natural resource requirements normalized to a gigawatt-electricity-per-year basis. Another impact is the slightly higher discharge burnup, resulting in somewhat different activity levels of the spent nuclear fuel and high-level waste radioactivity at 100 and 100,000 years after fuel discharge. The environmental impacts—including land use, water use, carbon emission, and radiological exposure—are of the same magnitude per unit energy generated. Finally, however, the impacts are distributed differently. Less than 5% enrichment has marginally more impact on the back-end of the fuel cycle, and greater than 5% enrichment has marginally more impact on the front-end of the fuel cycle. Ultimately, no neutronic or reactor safety hindrances to employing light water reactor fuel with enrichments greater than 5% are identified; given the achievable reactor performance benefits with advanced fuels, further practical exploration of increased enrichment fuel is recommended.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗